Here’s a laser cutting technique that makes thin plywood bendable. By cutting away elongated diamond shapes from the material, a lattice of strips connected minimally by alternating tabs is left over. The wood is then bendable, and it must be somewhat durable since the idea came from a product that uses the technique as a hinged notebook enclosure.

We don’t have much interest in it as an often used pivot point as surely it must be a problem with long-term use. But we love the look of it as a rounded corner on an enclosure like the Arduino project box seen above. The side walls are one continuous piece, with identical top and bottom sections which receive the alignment tabs. The whole thing is held together with just four bolt/washer/nut combinations.

But if you don’t have access to a laser cutter, we guess you’ll have to stick to altering pre-made enclosures for now.

What makes a project really exceptional? Part of it is a, ‘gee, that’s clever’ angle with a little bit of, ‘that’s actually possible.’ One thing the Hack a Day crew really appreciates is awesome enclosures. Altoids tins will get you far, but to step up to the big leagues you’ve got to bend some aluminum. Luckily, [Rupert] sent in a great tutorial on bending aluminum sheets for enclosures.

To make his press brake, [Rupert] scavenged a few pieces of 38mm bamboo worktop scraps. After assembling a few of these pieces with some hinges, he was ready to bend some aluminum.

One trick [Rupert] picked up is scoring the sheet metal on the inside of a future bend. For [Rupert]‘s project, he sent his 3mm aluminum sheet through a table saw set to cut 1mm deep. Of course this should only be done with a blade designed for non-ferrous metals with as many carbide teeth as possible. Judging from [Rupert]‘s homebuilt Hi-Fi that used this construction technique, the results are phenomenal.

The quest for a project box is always a balance between cost, complexity, and style. We think [Pcmofo] really finds the mark with his exterior electrical box enclosures. He took the time to document his fabrication process for those that want to replicate his look.

These grey plastic boxes are meant to keep the elements away from home and commercial electrical systems. They’re easy to find and come in many different sizes (this one is 8″ square and 4″ deep). The plastic is very rigid, but still easy enough to work with simple tools.

[Pcmofo] starts by eyeballing the placement of his components. Once he has a good idea of where each should be located he grabs a caliper and uses Adobe Illustrator or Inkscape to design a template. This is attached with painter’s tape, and rough openings are made using a drill press. The holes are brought to the final size by hand using files for a nice finished edge. When it comes time to mount hardware, the plastic is strong enough to hold threads if you are careful when using the tap to cut them.

The example enclosure houses a temperature controller for fermenting beer. You can see some video of the enclosure embedded after the break.

[Karl] wrote in to tell us about a software package called EagleUp that will import your Eagle CAD PCB designs into Google SketchUp. It bridges the gap between the two using the open source image processing software ImageMagick.

As you can see above, you’ll end up with a beautifully rendered 3D model of your hardware. This is a wonderful way to make sure that your enclosure designs are going to work without needing to wait for the PCBs to arrive from the fab house. It is available for Windows, OSX and Linux (although the last time we tried to run Sketchup under Wine nothing good came of it — perhaps it’s time to try again).

In [Karl's] case, he’s working on an Arduino compatible board based around the Xmega. He mentions that EagleUp is a great way to get an idea of how component placement will end up, and to see if the silk screen layer is going to turn out well or not. Here’s a link to one of his test designs.

If you ask us, there’s no substitute for learning by doing. But often the hardest part of acquiring new skills is coming up with the idea for a project that utilizes them. [Mike Rankin] wanted to develop a project using laser cut acrylic, and settled on building a control box for an RGB LED strip. He got some practice modeling objects in SolidWorks and seeing the process through to the final build. But it also let him explore an area of microcontroller programming in which he had little experience.

The LED strip he’s using depends on the HL1606. This is an SPI addressable chip that we see popping up in a lot of projects these days. It’s pretty simple to send red, green, and blue values through the data bus, and it allowed [Mike] to try his hand at programming menus and sub-menus. The controller takes input from a clickable rotary encoder. The settings are displayed on an OLED screen, with all the hardware nestled comfortably in his custom-cut enclosure.

Don’t miss the demo video embedded after the break.

Quite often, we see project boxes that seem to be constructed more as an afterthought than anything else. That’s not to say there is anything wrong with stuffing your latest creation into a nondescript black box, or even cardboard if it happens to fit your needs. Sometimes however, an enclosure embodies the spirit of a project, making it all that much cooler.

[Adam] recently picked up a copy of Make magazine and decided to build their “Luna Mod”, a sound effects generator and looper based on a PICAXE-08M. Aside from the micro controller the Luna Mod includes a couple of pots, a switch, and a few LEDs – nothing incredibly striking. Once he had everything assembled on a strip of protoboard, he started working on his enclosure.

The enclosure is made from an old record, which after some trial and error, [Adam] got just right. The record was heated and cut, then bent into shape. While it’s not necessarily a hack, we think it looks pretty slick. It really fits the theme of the Luna Mod and is far more attractive than a plain plastic box.

Stick around to see his sound generator in action.

[Loreno Minati] built his own stir plate out of a hard drive enclosure. It’s the exact same hack as the one we saw a few weeks ago. A magnet was glued to the center of a computer fan, which causes the magnetic capsule inside the beaker to spin. This creates a vortex, evenly mixing the liquid.

Using a hard drive enclosure is a brilliant idea. It’s designed to sit in plain sight so you get a very nice finished look. It’s also exactly the right size for the fan itself. A potentiometer mounted in the cap of the enclosure allows for variable speeds, and the DC barrel jack is being used for the power source. Now that we think of it, this may be the best use of an external HDD enclosure we’ve ever seen (even eclipsing its original purpose). Check out a video and image gallery of the project after the break.

We’ve categorized this as a beer hack since stir plates are often built by hobbyists for growing yeast starters used in home brewing.

[Thanks Jorge]

Building a great looking box for your projects can be a challenge. [Ken] boils down his process of building enclosures out of copper clad (PDF) circuit board material into an illustrated guide in case you want to try this for yourself. Why would you want to use PC board? The fiberglass substrate makes for a strong and lightweight material. Also, [Ken] is a ham radio operator and the copper coating acts as an electrical shield for delicate components inside.

As you can see above he uses solder to tack the pieces together. There’s some important considerations that go along with this method. First, he cuts the pieces just a bit oversized and then sands them flat and square before assembly. Next, he uses some 20 gauge wire as a shim between a ninety-degree joint and a right angle jig. This shim compensates for the shrinking that occurs as the solder cools, making sure the joint gets pulled to a right angle. He even solders nuts in place so that screws can be used to attach the case cover to the chassis.

Yesterday we saw toner transfer used to make labels on an ABS case. If you make your enclosure out of copper clad, using toner transfer for panel labels will be a snap!

[Stephen Eaton] created an enclosure and shared his process in a pair of blog post. We thought is was amusing that he remarks on how rarely his projects get the to point that you’d want to make an enclosure for them. We’ve certainly got a lot of bare-PCB creations lying around. But when it does come time, we think his fabrication method is a good way to go.

First of all, he didn’t start from scratch. He already had a SparkFun project case sitting around. The problem is figuring how to make it work for your situation. We’ve used a drill, a Dremel, and a file in the past and that yields passable results but nothing that would be mistaken for anything other than a carefully mangled project box. [Stephen] decided to mill the openings he needed from the box, which yielded professional looking results. He started by emailing SparkFun and asking if they could give him a 3D model of the project box and the obliged. He then modeled the LCD screen, LED light pipes, button, USB port, and SD socket. From there it was off to the mill with a custom jig and a few tricks we think you’ll appreciate. The end result is just another reason to build the CNC mill you’ve had on your mind for so long.

Who needs metal, wood, or acrylic if you are talented with duct tape? This server is housed in a 20-sided enclosure made entirely of duct tape, 22 rolls of it. A team of seven completed the project after eight build session over the course of about ten days. It’s currently in use at this year’s MillionManLan 9 as confirmed by this incredibly boring live feed.

However whimsical, we do appreciate the build process. Tubes are rolled until they reach the specified thickness, then cut to length on a chop saw. More sticky stuff is applied to the joints and piece by piece the frame comes together. From the diagram laying off to the side in one of the pictures it looks like they did the smart thing by designing this in CAD before getting their hands dirty sticky.

[Riley Porter] has been working on several different custom enclosure designs. Above, you can see his Proto Desk which holds a breadboard, Arduino, and has two recessed boxes with sliding tops for components and patch wires. He’s got a miniature version that gets rid of the breadboard, as well as slick-looking cases for the Bus Pirate, tinyISP, and face plates for word clocks.

Well, if you’ve got a laser cutter you should be using it right? We’ve seen [Riley's] wares in the past; he wrote the guide for laser cutting solder stencils.

[Thanks Brian]

This clear rubber puck serves as the enclosure for a diy mp3 player. The wires encapsulated in the rubber are just there for looks but the utility of using this material as a case is fascinating.  Alas, there’s no details on the material other than that it’s clear rubber. Update: [Reboots] picked up on some info that we originally missed. Looks like this is made from some Smooth-On PCM 780 urethane rubber.

We’ve looked into casting our own molds from silicone rubber in the past.  That may be the process used here but we can’t tell what allows the two halves to be pried apart. We’ve embedded video after the break that details casting rubber around a part in one solid block, then cutting the rubber off of that to create a mold. We’re also familiar with the mold making kits from Tap plastics but as far as we know, they’re always colored and never clear.

We keep our eyes peeled for new prototyping products and we want to know more about the materials and the process used to make this cylindrical elastomer. If you’ve got the goods on how this is done, please share them in the comments.

[via Gizmo Watch]

Nothing Earth-shattering here. Just, dare we say it, really cute!

The venerable Altoids mint tin has become an icon of the maker culture. Browsing through past articles on Hack a Day, Adafruit or Instructables, you’ll find project after project for which these pocket-sized enclosures provided just the right fit. Eminently practical, affordable, but the aesthetics have occasionally left something to be desired.

We recently stumbled upon these nifty gift card holders that resemble miniature versions of current-generation game consoles. They might be the perfect housing for your next microcontroller project…

These were acquired from our local GameStop retail store and unfortunately do not appear to be available online. Each will set you back $2.99 — about a buck more than the mints, and without the added benefit of fresh breath. Such is the price of style.

The shapes are varied, but all are a bit larger than the traditional Altoids tin, allowing ample space for a battery pack, breadboard or microcontroller setup. As with the mint tins, of course you’ll want to insulate your project from the interior metal surface. A bit of contact paper or even some index cards are usually sufficient.

In addition to the Xbox 360, Wii and Playstation 3 tins depicted here, portable consoles — the PSP and Nintendo DS Lite — are also available in miniature form.

This is a “why didn’t I think of that?” idea. [Alec] needed a way to connect an IDE DVD drive using USB. Rather than order a connector he pulled the circuit board out of an old USB hard drive enclosure and connected to his DVD drive. Bang, recognized and running.

This will prove extremely handy if you have a netbook without an optical drive. We’ve used Unetbootin to move Linux ISO images to a thumb drive in the past. In addition to getting around the lack of an optical drive, this saves burning the data to a piece of plastic. But, you should be able to use this with a Leopard retail DVD instead of a 16GB thumb drive for a Hackintosh conversion. That means you could install Leopard on a netbook without needing a Mac to transfer the disk image to your thumb drive first.

[Dennis] got snowed in after the biggest storm in the history of the state hit. Like any good hacker he didn’t let the time go to waste. He decided to dig out his Neo Freerunner to give it a decent battery and a new OS.

The original battery for the Freerunner has a controller board integrated into the package. [Dennis] pulled out the board and attached it to a portable DVD player battery. After running it through a discharge cycle with another hack of his, the board learned the new battery capacity. The larger battery plus a fast-charger from SparkFun required a larger case. He made it happen by combining a 2.5″ HDD case with the original body courtesy of some JB weld. The final portion of the hack was to load up Android which is as simple as untarring the package onto an SD card.

It’s a bit big, but the battery will last and he’s got an open platform. Nice work!